Abstract

UD Anugerah Makmur Jaya is a manufacturer of ceramic lists in Dukuh Kupang Surabaya. The production process is started from the cutting process, printing and ovening the ceramic in a high temperature kiln. According to preliminary interview and data collection there were identified some problems that correlated with complaint and painful on operator body segments and uncomfortable environment especially noise from the cutting machine (127.59 dB). To support the problem identification then time study was done and the production reject/scrap was recorded too. The average ceramic cutting time was 8.7 second/piece while the reject rate of cutting process was 6.6%. The next problem according to the management was accidental rate. From the initial data collection and analysis on the working method using Nordic Body Map questionnaire, it could he known that several body segments such as back, low back, waist have the highest painful score (1.194). Using the REBA analysis, it was known that the REBA score was 12 (the working risk level was very high)and it might be improved immediately On the energy consumption point of view it could he seen that the energy consumption rate for ceramic cutting was 2 kcal/min.
To overcome those problems then the working facility especially ceramic cutting machine, was redesigned and facilitated with a new jig. As the supporting system to reduce the working accidental rate then the operators had the duty of using the safety working equipments, such as safety glasses jacket earplug and also safety gloves By redesigning the initial ceramic cutting machine and supported some jigs and safety equipments on the production floor then some improvements were achieved The improvements were: body map score reduction to 0.33 (72.09% reduction). REBA scorereductionto4(medium risk)average ceramic cutting time reduction to 4.49 second per piece (48.3% reduction)energy consumption reduction to 1.6 kcal/minute(20% reduction noise reduction to 118.82111 dB, heart pulse/minute reduction from 116.6 pulse/minute to 102.4 pulse/minute)and finally the reject scrap of cutting process had been reduced to 1%.